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Fabrication Methods Fabrication

Methods

Forming Casting Machining Miscellaneous

Powder
Forging Drawing Extrusion Rolling Sand Dye Investment Continuous Joining
Metallurgy

Casting Casting
Die casting Extremely smooth High initial die
In this process, highly fluid metal surface, excellent cost, limited to
is forced, under pressure, and the dimensional non-ferrous
Process Advantages Limitations pressure is maintained until accuracy, rapid metals, size of
Sand casting Any metal & in any Some machining solidification is complete. production parts is limited.
Sand is used for mould making size and shape, is required,
low tool cast rough surface, Centrifugal casting No crevices because Alloys can not be
A true centrifugal casting process of the centrifugal distributed evenly,
Investment casting High dimensional Size of parts are consists of pouring molten metal action, good outer limited to small
This is often referred to as accuracy, limited, high into a revolving mould, surface, intrinsic casting.
‘precision casting’. The smoother labor cost, centrifugal action forces the
mould is made by pouring surface, small extensive metal tightly against the mould.
investment material around parts are patterns and The metal solidifies having an
the wax pattern and allowing produced mostly. moulds. outer surface which confirms to
it to harden. the mould’s shape and a surface
of revolution on the inside.

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Forming is done by two ways Joining

HOT WORKING COLD WORKING • Soldering and Brazing
 The deformation is achieved at a  In this process the deformation is - Joint is made with the added material
temperature well above that at takes place at the temperature well radically different in composition from the
which re-crystallization can takes below that of the crystallization
place. temperature. base materials and having sufficiently
 Large deformations are possible.  Large deformations are not lower melting point than the base metals.
possible.
 Will not get good finished  Will get good finished products at
products. the end.
 Mechanical properties are not  Good mechanical properties are
good. achieved.

Various types of brazing 2 Dip Brazing

• In dip brazing components with filler metal
1. Torch Brazing
in proper form is preplaced at the joint and
• Torch brazing utilizes the heat of oxy- assembly is dipped in bath of molten salt
acetylene flame with neutral or reducing which acts as heat source as well as flux
flame. Filler metal may be either preplaced for brazing. Preplaced preform melts and
in form of washers, rings, formed strips, fills the joint. Another variant is to dip
powders or may be fed manually in form of assembled parts in metallic bath and metal
rod. of bath fills the joint.

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3. Furnace Brazing 3. Infra-red Brazing

• Self fixturing assembly with preplaced filler • The heat for brazing is obtained from infra-
metal is placed inside electrically heated red lamps. Heat rays can be concentrated
furnace with temperature control for at desired area or spot with concave
heating and cooling. These furnaces may reflectors. Such method of brazing
also be using protective atmosphere with requires automation and parts to be joined
inert gases like argon and helium or should be self fixturing. Filler metal is to be
vacuum for brazing of reactive metal preplaced in the joint. The operation can
components. be performed in air or in inert atmosphere
or in vacuum.

4. Induction Brazing 5 Resistance Brazing

• The heat is generated by induced current • In resistance brazing the heat is generated
into the workpiece from a water cooled coil at the interfaces to be brazed by resistive
which surrounds the workpieces to be heating. The components are connected
brazed. High frequencies employed vary to high current and low voltage power
from 5 to 400 kHz. Higher the frequency of supply through two electrodes under
current, shallow is the heating effect while pressure. Only those fluxes are used
lower frequencies of current lead to which are electrically conductive and filler
deeper heating and so it can be employed metal is preplaced.
for thicker sections. Fluxes may or may
not be used during brazing.

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Classification of Welding
Welding
Processes:
• Welding which is the process of joining two • Fusion welding.
metallic components for the desired purpose,
• Pressure welding.
can be defined as the process of joining two
similar or dissimilar metallic components with the
application of heat, with or without the
application of pressure and with or without the
use of filler metal. Heat may be obtained by
chemical reaction, electric arc, electrical
resistance, frictional heat, sound and light
energy. If no filter metal is used during welding
then it is termed as ‘Autogenous Welding
Process'.

Pressure Welding
Classification of Fusion Welding

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Type of welded Joints Fusion-Welding

• Gas Welding
 Combustible gas mixture (C2H2 + O2)
• Groove Welding  Preferred for thin metal plates.
 Very difficult to control the process.
• Electric arc welding
• Filleted Welding  Better control over process
 Less energy for welding
• Submerged welding
• Plug Welding  Electric arc below blanket of granulated mineral flux.
 Can’t see the flame so very difficult to control
• ASME Sec IX is widely used standard for welding
• BS 5500 and IS 2825 : 1969 are also used.

Most Common Weld Defects Weld Check

• Poor weld shape due to misalignment of the parts being • Strength of weld depends on type of joint
welded. and quality of welding.
• Cracks in welds or heat affected zones of the base metal.
• Soundness of weld is checked by seam
• Pinholes on the weld surface weld test.
• Slag inclusion or porosity in the forms of voids.
• Spot or visual test
• Incomplete fusion between weld beads or weld and base
metal • Powder test
• Lack or insufficient penetration of weld metal in joints • Dye fluorescence test
• Undercutting, an intermittent or continuous groove • Non destructive testing
adjacent to weld left unfilled by weld metal

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Correction Machining
• The possible lower strength of welded joint • Machining is done to achieve the exact
compared to the virgin plate is done by dimension of the parts of vessel, flange
multiplying the allowable stress for faces, tube sheet etc.
selected MoC by “Welding Joint • Exact surfaces and thickness are achieved
Efficiency Factor” J. • For high pressure services equipments are
formed by series of concentric shells.
• Drilling, boring, Milling, Grinding,
Polishing, Turning

NON-DESTRUCTIVE TESTING Radiography

• Radiography • This method of flaw detection is, essentially, based on the
radiation passing through the object and variation in its
• Ultrasonic thickness and/or density being revealed by the localized
• Magnetic particle and magnaflux differences in the thickness of the film image, the radiation
used being either X-rays or Gamma rays.
• Liquid dye penetrate testing • Radiography has been specified in the various codes of
• Eddy current testing construction as a mandatory test for fusion welds in class
I pressure vessels. The extent of radiography specified,
1. No one method provides a universal test for detection of all types of
i.e., 100 percent or spot radiography is a design
defects and the various methods are both supplementary and
parameter and would depend upon the joint efficiency
factor radiography is a design thickness of the
complimentary to each other.
components.
2. The evidence of a defect provide by many methods of non-destructive
testing is indirect and therefore the direct observation made are • The quality of a film governed by two aspects:
sometimes susceptible to variation in their interpretation due to the Density
human factor involved. Contrast